Robot system and method for inspecting and repairing casts in smelting processes

ABSTRACT

At present, the repair of casts as it is done today has the disadvantage of being carried out manually or in a semiautomatic way which means less efficiency in the system and the superficial inspection has the disadvantage of being carried out in many occasions with low levels of vision advanced technology application. Due to the above a robot system and method for the repair and/or inspection of cast surfaces in an automated way have been developed. The robotic system is composed mainly of a robotic manipulator of at least 4 degrees of freedom, and a gripping mechanism which allows to take the repair device from a tool holder rack located at one of its sides, moving it through a defined path to the repair and inspection area, where a repair process will be carried out in a sequential and programmed way to a number of cast faces to be defined. Additionally, the configuration of this system allows to carry out an inspection process of the surfaces in a sequential and programmed way through the use of a vision system by taking from a tool holder rack or carrying an advanced vision system for the inspection of surfaces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional patent applicationSer. No. 60/734,984 filed 2005 Nov. 10 by the present inventor

FEDERAL SPONSORED RESEARCH

Not Applicable

SEQUENCE LISTING OR PROGRAM

Not Applicable

BACKGROUND—FIELD OF INVENTION

This invention relates to the use of robotic technology in miningindustry, specifically in smelting processes.

BACKGROUND—PRIOR ART

During metal obtention and refining processes, smelting furnaces areused to cast metal concentrates for purifying and extracting them. Thefirst stage of the productive process is to move the dry concentrate toone of these furnaces, which could be a flash furnace and/or a Tenienteconverter, where casting is at temperatures over 1.200° C. In this way,while the concentrate becomes a molten liquid mass, its components arebeing separated and combined to form a two layer bath. The heaviestlayer is called matte and it is a metal enriched component. Over thislayer, the slag is floating, which is a coat of impurities of the metalof interest. In this way and during successive stages, the stage whichis rich in the metal is sequentially cast and refined through severalfurnaces which allows to obtain a high purity metal.

In the last stage of the smelting process, the fire refining stage iscarried out in which the metal is processed in rotary furnaces, byadding special purifying agents which are called fluidizing agents tooxide and eliminate all the impurities with the resulting effect of veryfew non desired elements contained in the molten bath. Then, the oxygenis extracted with steam or oil injections with the final result of ahigh purity level.

Thus, when a metal load reaches the required purity level, the furnaceis inclined and in exact quantities the metal is poured into one of theingot casts of the fire refined cast casting wheel. Once the metal ispoured into the cast, the wheel rotates to advance the following castinto position and other ingot is cast. In this way, the wheel speed isadjusted in an accurate way to the optimum speed profile, ensuring asmooth acceleration and disacceleration level of the casts. This isintended to produce high quality ingots with a minimum burr formationgrade.

To finish the smelting process, the dislodging process (stripping and/orextraction) proceeds in which the cast ingots are lifted and sent to acooling tank to avoid the excessive oxidation and to obtain a deepscrubbing.

Finally, the cast ingots are counted and arranged in predeterminedbundles or at distances required by the electrolytic plant. Thedischarge of cooling tanks is carried out whether by a forklift or byanode lifting device.

Once the casting process has been ended, the casts are reviewed andthose presenting cracks or adherence of material are removed for repair.They are later reinstalled in the casting wheel.

Particularly, the repair of casts in the way it is performed today hasthe disadvantage of being carried out manually or in a semiautomatic waywhich means less efficiency of the system. On the other hand thesuperficial inspection has the disadvantage of being performed visuallyin many cases or with low levels of advanced technology visionapplications. Similarly, in many cases, the operators are subjected to ahigh physical demand and harsh environmental conditions.

SUMMARY

A robot system and method for the repair and/or inspection of castsurfaces in an automated way have been developed.

DRAWINGS—FIGURES

FIG. 1. View of a robotic manipulator repairing (caulking) a cast

FIG. 2. View of a robotic manipulator repairing (caulking) a cast

FIG. 3. General layout of a robot system repairing and inspecting ofcast surfaces

DRAWINGS—REFERENCE NUMERALS

1. Robotic manipulator

2. Gripping mechanism

3. Repair device

4. Repair and inspection area

5. Casts

DETAILED DESCRIPTION

This invention relates to a new robot system as well as a robotic methodfor the repair and/or inspection of cast surfaces in an automated waywhich is carried out automatically through anthropomorphous robotic armsof at least 4 degrees of freedom, which are installed at one side of therepair and inspection area in the copper field.

With reference to FIG. 1, FIG. 2, and FIG. 3, the robot system iscomposed mainly of one robotic manipulator (1) of at least 4 degrees offreedom, provided with a communication, acquisition and control system,and a gripping mechanism (2) to allow to take the repair device (3) froma tool holder rack located at one of its sides, which is moved through adefined path to the repair and inspection area (4), where the hammeringprocess is carried out in a sequential and programmed way, to a numberof faces to be defined of the casts (5).

Additionally the configuration of this system allows an inspectionprocess of the surface in a sequential and programmed way through asecond tool provided with an advanced vision system for the surfaceinspection from a tool holder rack or it could be mounted on the roboticarm.

1. A robot system for the repair and/or inspection of cast surfaces inmetal smelting processes comprising an anthropomorphous robotic arm ofat least 4 degrees of freedom, one control, communication andprogramming unit, one gripper adapter, one pneumatic gripper, onepneumatic gripper driving system, one electric supply system, one repairsystem, one advanced vision system for the inspection of surfaces and atool holder wherein the anthropomorphous robotic arm of at least 4degrees of freedom is provided with a pneumatic gripping mechanism whichallows in a sequential and programmed way to take, manipulate andrelease, from a tool holder rack, a repair device and/or an advancedvision system for the inspection of surfaces, in such a way that itmoves it through a defined path to the cast surface, in which the repairand inspection process of surfaces in different paths within the workvolume of the robot system.
 2. A robot system for the repair and/orinspection of cast surfaces in metal smelting processes according toclaim 1, wherein the anthropomorphous robotic arm of at least 4 degreesof freedom is provided with a pneumatic gripping mechanism which allowsto take, manipulate and release, a repair device and/or system of visionadvanced inspection of surfaces to carry out the repair and inspectionof surfaces in different paths within the work volume of the robotsystem.
 3. A robot system for the repair and/or inspection of castsurfaces in metal smelting processes according to claim 1, wherein theanthropomorphous robotic arm of at least 4 degrees of freedom has thecapacity to take, manipulate and release a repair device and/or systemof vision advanced inspection of surfaces and move it in different pathswithin the work volume of the robotic system.
 4. A robot system for therepair and/or inspection of cast surfaces in metal smelting processesaccording to claim 1, wherein the anthropomorphous robotic arm of atleast 4 degrees of freedom is provided with a gripping mechanism whichallows in a sequential and programmed way to take, manipulate andrelease a repair device and/or system of vision advanced inspection ofsurfaces and moves it in different paths within the work volume of therobotic system.
 5. A robot system for the repair and/or inspection ofcast surfaces in metal smelting processes according to claim 1, whereinthe anthropomorphous robotic manipulator could communicate by itself orthrough a PLC interface with the control system.
 6. A robot system forthe repair and/or inspection of cast surfaces in metal smeltingprocesses according to claim 1, wherein the anthropomorphous roboticmanipulator has the capacity to obtain and interpret the informationfrom installed analogue and/or digital sensors.
 7. A robot system forthe repair and/or inspection of cast surfaces in metal smeltingprocesses according to claim 1, wherein the anthropomorphous roboticmanipulator has the capacity to generate analogue and/or digital signalsto control analogue and/or digital input devices.
 8. A robot system forthe repair and/or inspection of cast surfaces in metal smeltingprocesses according to claim 1, wherein the anthropomorphous roboticmanipulator of at least 4 degrees of freedom is mounted on a fixedand/or mobile system.
 9. A robot system for the repair and/or inspectionof cast surfaces in metal smelting processes according to claim 1,wherein the anthropomorphous robotic manipulator has an electricalsystem driven by three-stage induction motors, with vectorial and/orscalar control.
 10. A robot system for the repair and/or inspection ofcast surfaces in metal smelting processes according to claim 1, whereinproductivity and efficiency of the repair and inspection of castsurfaces increases.
 11. A robot system for the repair and/or inspectionof cast surfaces in metal smelting processes according to claim 1,wherein it could be integrated not only to repair and inspectionprocesses of cast surfaces, but also it could be used for carrying outrepair and inspection of surfaces, either selectively or compositum, ina wide range of other industrial productive processes.
 12. A robotsystem for the repair and/or inspection of cast surfaces in metalsmelting processes according to claim 1, wherein it has the capacity tomove and manipulate the different tools in different paths within thework volume of the robotic system.
 13. A robot system for the repairand/or inspection of cast surfaces in metal smelting processes accordingto claim 1, wherein the system may operate automatically, orsemi-automatically, and also allows solutions scalability.
 14. A robotsystem for the repair and/or inspection of cast surfaces in metalsmelting processes according to claim 1, wherein it allows the finaluser of the technology to use the system in a modular way by allowing tocarry out the repair and inspection either selectively, independently,separately or compositum.
 15. A robot system for the repair and/orinspection of cast surfaces in metal smelting processes according toclaim 1, wherein it allows the final user of the technology uses onlyone or two of the repair and/or inspection activities of cast surfaces,either selectively or compositum, according to the requirements.
 16. Arobotic method for the repair and/or inspection of cast surfaces inmetal smelting processes using the robot System of claim 1 to 15,wherein the anthropomorphous robotic arm of at least 4 degrees offreedom is provided with a pneumatic gripping mechanism which allows ina sequential and programmed way to take, manipulate and release, from atool holder, an advanced repair device and/or system of vision ofsurfaces, in such a way to move it, through a defined path to the castsurface, in which the repair and inspection process of surfaces iscarried out in different paths within the work volume of the roboticsystem.
 17. A robotic method for the repair and/or inspection of castsurfaces in metal smelting processes using the robot System of claim 1to 15, wherein the anthropomorphous robotic arm of at least 4 degrees offreedom, is provided with a pneumatic gripping mechanism which allows totake, manipulate and release a repair and/or system of vision advancedof inspection of surfaces to carry put the repair and inspection ofsurfaces in different paths within the work volume of the roboticsystem.
 18. A robotic method for the repair and/or inspection of castsurfaces in metal smelting processes using the robot System of claim 1to 15, wherein the anthropomorphous robotic manipulator of at least 4degrees of freedom which allows to take, manipulate and release a repairdevice and/or system of vision advanced of inspection of surfaces andmoves it in different paths within the work volume of the roboticsystem.
 19. A robotic method for the repair and/or inspection of castsurfaces in metal smelting processes using the robot System of claim 1to 15, wherein the anthropomorphous robotic manipulator couldcommunicate by itself or through a PLC interface with the controlsystem.
 20. A robotic method for the repair and/or inspection of castsurfaces in metal smelting processes using the robot System of claim 1to 15, wherein the anthropomorphous robotic manipulator has the capacityto obtain and interpret the information from installed analogue and/ordigital sensors.
 21. A robotic method for the repair and/or inspectionof cast surfaces in metal smelting processes using the robot System ofclaim 1 to 15, wherein the anthropomorphous robotic manipulator has thecapacity to generate analogue and/or digital signals to control analogueand/or digital input devices.
 22. A robotic method for the repair and/orinspection of cast surfaces in metal smelting processes using the robotSystem of claim 1 to 15, wherein the anthropomorphous roboticmanipulator of at least 4 degrees of freedom has a gripping mechanismwhich allows to take, manipulate and release, in a sequential andprogrammed way, a repair device and/or system of inspection of surfacesand move it in different paths within the work volume of the roboticsystem.
 23. A robotic method for the repair and/or inspection of castsurfaces in metal smelting processes using the robot System of claim 1to 15, wherein the anthropomorphous robotic manipulator of at least 4degrees of freedom is mounted on a fixed and/or mobile system.
 24. Arobotic method for the repair and/or inspection of cast surfaces inmetal smelting processes using the robot System of claim 1 to 15,wherein the anthropomorphous robotic manipulator has an electricalsystem driven by three-stage induction motors with vectorial and/orscalar control.
 25. A robotic method for the repair and/or inspection ofcast surfaces in metal smelting processes using the robot System ofclaim 1 to 15, wherein productivity and efficiency of the repair andinspection of cast surfaces increases.
 26. A robotic method for therepair and/or inspection of cast surfaces in metal smelting processesusing the robot System of claim 1 to 15, wherein it could be integratednot only in the processes of repair and inspection of cast surfaces, butalso it could be used to carry out the repair and inspection ofsurfaces, either in a selective way or compositum, in a wide range ofother industrial productive processes.
 27. A robotic method for therepair and/or inspection of cast surfaces in metal smelting processesusing the robot System of claim 1 to 15, wherein it has the capacity tomove and manipulate the different tools in different paths within thework volume of the robotic manipulator.
 28. A robotic method for therepair and/or inspection of cast surfaces in metal smelting processesusing the robot System of claim 1 to 12, wherein the system may operateautomatically or semi-automatically, and also allows solutionscalability.
 29. A robotic method for the repair and/or inspection ofcast surfaces in metal smelting processes using the robot System ofclaim 1 to 15, wherein it allows the final user of the technology to usethe system in a modulate way, allowing to carry out the repair andinspection in a selective, independent, separately or compositum way.30. A robotic method for the repair and/or inspection of cast surfacesin metal smelting processes using the robot System of claim 1 to 15,wherein it allows the final user of the technology to use one or two ofthe repair and inspections activities of cast surfaces, eitherselectively or compositum, according to the requirements.